EP1096047A1 - Vorrichtung, Verfahren und System zur Ausbreitung eines Faserbündels durch Luftstrahlen und damit hergestellte Faserbahn - Google Patents

Vorrichtung, Verfahren und System zur Ausbreitung eines Faserbündels durch Luftstrahlen und damit hergestellte Faserbahn Download PDF

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Publication number
EP1096047A1
EP1096047A1 EP00122227A EP00122227A EP1096047A1 EP 1096047 A1 EP1096047 A1 EP 1096047A1 EP 00122227 A EP00122227 A EP 00122227A EP 00122227 A EP00122227 A EP 00122227A EP 1096047 A1 EP1096047 A1 EP 1096047A1
Authority
EP
European Patent Office
Prior art keywords
tow
band
opening
air
tow band
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP00122227A
Other languages
English (en)
French (fr)
Inventor
Todd Ames
Bobby Ray Lomax
William Thomas Wygand
Ricky Lee Kenley
William West
Jean-Claude Abed
Edward J. Powers
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Celanese Acetate LLC
Original Assignee
Celanese Acetate LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US09/426,268 external-priority patent/US6253431B1/en
Priority claimed from US09/679,681 external-priority patent/US6543106B1/en
Application filed by Celanese Acetate LLC filed Critical Celanese Acetate LLC
Publication of EP1096047A1 publication Critical patent/EP1096047A1/de
Withdrawn legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/18—Separating or spreading
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G7/00—Breaking or opening fibre bales
    • D01G7/06—Details of apparatus or machines
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/12—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using stuffer boxes
    • D02G1/122—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using stuffer boxes introducing the filaments in the stuffer box by means of a fluid jet
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles

Definitions

  • This invention relates to systems which can be used to open a tow of fibers such that the resulting "opened tow" of fibers has a shape useful in the production of absorbent structures, and more particularly to an air opening jet apparatus and method for use in such systems and products formed by such systems.
  • fibers are sold as a “tow” in which a plurality of such fibers are compressed together, optionally with crimping, by methods known to those skilled in the art in order to maximize the content of the packing systems, for example, bales, by which such tows are sold and delivered to users of tow. Before use, such users generally "open” such tow, separating the compressed fibers by a distance greater than that in the compressed state. Numerous methods and devices for opening tows are known and described in the art. Examples include U. S. Patent Nos.
  • This low pressure air is utilized to move the tow through the air opening jet, during which the tow is opened, and then through a bustle assembly in which the opened tow is decelerated and retarded in the bustle assembly to obtain the desired opening and density of the tow.
  • This deceleration and retarding of the tow is obtained by an adjustable tension arrangement for engaging the tow, and more particularly by a flat, imperforate "tension" plate that is pivotally mounted at one of its ends within the bustle assembly, and a relatively complex mechanical arrangement for adjusting the movement of the pivoted tension plate toward and away from the tow to thereby vary the tension force applied to the tow by the tension plate.
  • an air opening jet apparatus for use in a system for opening a thin, relatively wide tow of textile filaments held together by crimping and forming the opened tow into a predetermined shape suitable for use, for example, as an absorbent structure for personal care products.
  • the air opening jet apparatus includes a housing having an inlet opening for receiving a partially opened tow and having a configuration corresponding generally to the shape of the partially opened tow.
  • the housing also has an outlet opening through which the tow exits the housing and this outlet opening has a configuration corresponding generally to the predetermined shape.
  • An air jet is formed within the housing adjacent the inlet opening thereof to create a venturi which moves the tow through the air opening jet apparatus and which also further opens the tow, and a source of compressed air communicates with the air jet to provide carrier air for moving the tow through the air opening jet apparatus.
  • a forming chamber is provided within the housing and downstream of the air jet that includes a gradually increasing cross-sectional area in the direction of flow of the tow that corresponds to the predetermined shape, the air jet being disposed within the housing to cause the tow to be fully opened and to substantially fill the forming chamber as it moves therethrough.
  • An accumulating chamber is located within the housing downstream of the forming chamber that is constructed and arranged to permit the opened tow to accumulate within the accumulating chamber and be withdrawn from the housing at different flow rates through the housing outlet opening in the predetermined shape.
  • the accumulating chamber includes at least one perforated plate disposed in the path of the tow and the carrier air moving therethrough to cause the tow to engage the perforated plate and to cause at least some of the carrier air to pass through the perforated plate.
  • a control valve is provided for maintaining the flow of the carrier air at a level that will cause at least the portion of the carrier air to pass through the perforated plate and urge the tow into frictional engagement with the perforated plate with sufficient force to retard the movement of the tow through the accumulating chamber and cause the tow to accumulate in the accumulating chamber.
  • the accumulating chamber may include a second perforated plate located in spaced relation to the first above mentioned perforated plate, and the tow moves between the perforated plates and is urged into engagement therewith by the carrier air passing through both the perforated plates.
  • the predetermined shape of the outlet opening in the housing is rectangular.
  • Another aspect of the present invention provides an apparatus and method by which one or more air opening jets of the aforesaid type may be utilized for opening and forming multiple tows into a composite multi-tow band of a predetermined shape suitable for use, for example, as an absorbent structure for personal care products.
  • one or more air opening jets of the aforesaid type may be utilized for opening and forming multiple tows into a composite multi-tow band of a predetermined shape suitable for use, for example, as an absorbent structure for personal care products.
  • two separate and distinct tows are delivered to the inlet end of a single air opening jet or to separate air opening jets and are combined therein or downstream therefrom into a composite multi-tow band.
  • a first arrangement for receiving a first tow from a tow bale having a predetermined denier units per filament, spreading the filaments in the first tow into a first tow band, and having an exit end for discharging the first tow band therefrom with a predetermined width.
  • a second arrangement is provided for receiving a second tow from a second tow bale having a predetermined denier units per filament which is different from the predetermined denier of the first tow, spreading the filaments in the second tow into a second tow band, and having an exit end for discharging the second tow band therefrom with a predetermined width.
  • the first and second tow bands are then simultaneously introduced into the inlet end of the air opening jet apparatus and moved therethrough for opening and forming as described above in connection with a single tow.
  • the first and second tow bands can also be introduced to two separate air opening jet apparatuses.
  • Each of said first and second arrangements may preferably comprise a tow banding jet for receiving the respective first or second tow and spreading the tow into the form of a band, and at least one pair, and preferably multiple pairs, of delivery rolls disposed between the first and second banding jets, respectively, and the air opening jet apparatus or apparatuses.
  • the width of the exit end of one of the first or second banding arrangements is smaller than the other, whereby the multi-tow band discharged from the exit end of the air jet opening apparatus or apparatuses has one tow band that is larger in width than the other. It is preferred that the tow band having the larger width have a denier per filament that is less than the denier per filament of the other tow band.
  • the system may include a surfactant applicator located upstream of the inlet of the air opening jet for applying a surfactant to the tow band having a smaller width, and the system may include a bonding agent applicator located upstream of the inlet of the air opening jet for applying a bonding agent to the tow band having a larger width. It is also possible to individually vary the delivery speed of the two tow bands to the inlet of the air opening jet apparatus, and to individually control the bloom of the two tow bands.
  • a novel textile web is provided, preferably but not necessarily produced by the system apparatus and methodology above-described, wherein the web basically comprises a first and second tow each having multiple continuous textile filaments opened such that the filaments are deregistered with respect to one another.
  • the filaments of the first and second tow are commingled with each other within at least a portion of the web and may, for example, be commingled with each other essentially throughout the web or predominately along an interface between the first and second tow.
  • the first and second tow are generally layered with respect to each other within at least a portion of the web.
  • the filaments of the first and second tow may be of differing deniers per filament, which has been found to provide enhanced performance of the web in comparison with a comparable web made of a single tow of the same average denier per filaments. Additional components may be incorporated into the web, e.g., a super absorbent polymer for enhancing the liquid acquisition and absorption capabilities of the web. It is further contemplated that the filaments of at least one of the first and second tow may comprise a fusible bicomponent fiber for binding together the filaments of the first and second tow.
  • fiber as used herein means a filament, fiber or yarn of any material whatsoever; for example, cellulose acetate and triacetate, polyester, polyamide, polyolefin and similar polymeric substances.
  • bin means a plurality of fibers compressed together, optionally with “crimping” as such term is used and understood in art, by methods known to those skilled in the art in order to maximize the content of packaging systems by which such tows are sold and delivered, or to facilitate the transport of such plurality of fibers from one point to another point, for example, within a manufacturing facility.
  • the fibers comprising the tow may be made from any natural or synthetic substance, or mixture and/or blends thereof, including polyesters, polyamides, cellulose acetate and triacetate (collectively, an "acetate" tow), polypropylene oxide, polyethylene sulfide, liquid crystalline polymeric substances capable of being formed into fibers, polyamides, silk, wool, cotton, rayon, polyolefins, polyacrylates, polymethacrylates, and similar substances which can be made into fibers. Such fibers may or may not have a "finish" applied to them, depending upon their application.
  • an external finish is applied to such fibers so as to facilitate transport, although "internal" finishes, contained in the material used to form the fiber, may also be used and such fibers are included within the scope of the invention.
  • the fibers of the tow may be of any denier, tex, diameter or other cross-sectional or cross-section related size designation suitable for producing tow.
  • banding jet and “air banding jet” are used to signify a first tow opening device which utilizes air to spread a tow in a direction perpendicular to the direction of travel.
  • the “banding jet” is different and distinct from the “opening jet” or “air opening jet” also described herein.
  • an acetate tow may consist of about 2,500 to about 25,000 fibers having an individual denier of from about 1 to about 10, preferably of from about 3 to about 6.
  • the total denier for the entire tow, that is the assemblage of from about 2,500 to about 25,000 fibers, is thus from about 2,500 to about 250,000.
  • Acetate tows are generally of about 10,000 to about 20,000 fibers of individual denier of about 3 to about 6, giving rise to a tow having a total denier of about 30,000 to about 120,000.
  • the fibers of a tow should be uniformly or substantially uniformly distributed across the width/cross-section of the crimped tow bundle or band. This uniform fiber distribution is important to the process of opening a tow into a rectangular or substantially rectangular shape, and the more nearly uniform distribution of fibers the easier it will be to produce a rectangular or substantially rectangular opened tow.
  • Crimped and baled tows having a variety of width/cross-sections may be used in accordance with the invention, for example, about 25 mm (millimeters) to about 75 mm in width, preferably from about 40 mm to about 60 mm, and from about 1 mm to about 7 mm in height or thickness, preferably from about 2 mm to about 5 mm, with typical the dimensions being about 50 mm wide and about 3 mm thick.
  • an external finish may be applied to each fiber in a tow, such finish being in an amount from about 0.3% to about 5% by weight of the fiber bundle, preferably from about 0.5% to about 2.0 %.
  • the tows used in practicing the invention are generally "crimped tows" as the term is used and known to those skilled in the art. Crimping is done at about 5 to about 30 crimps per inch of uncrimped tow, preferably of from about 20 to about 25 crimps per inch of uncrimped tow.
  • a tow 14 may initially be fed through a conventional set of guides (not shown) to flatten and orient the tow 14.
  • the tow is then fed to a banding jet 130 of conventional design.
  • the banding jet evenly spreads the tow band in the direction perpendicular to the tow processing direction.
  • the air banding jet 130 used in these preferred embodiments can be any air banding jet known in the art, for example, as described in U.S. Patent No. 3,226,773, or in co-pending U. S. patent application Serial No.
  • roller pressure i.e., the force applied to the tow by the rollers 42 and 44, is from about 1 to about 25 psi, preferably from about 5 to about 15 psi.
  • the metal roller is element 42 (top roller) and the rubber roller is 44 (bottom roller).
  • roller assembly 60 comprising a driver metal roller 62 and a rubber roller 64, the metal roller 62 having circular grooves or being threaded or being a flat metal roller.
  • the tow is stretched, the stretching being accomplished by the drag associated with the nip pressure between rolls 42 and 44.
  • the nip pressure between the rollers of assembly 60 is from about 1 to about 40 psi, preferably from about 20 to about 30 psi.
  • tow 14 After emerging from assembly 60, tow 14 is passed by an optional first static eliminating bar 100 to remove any static charge which might be present on tow 14 and which might interfere with subsequent operations necessary in the formation of an absorbent structure.
  • roller assembly 70 comprising a driven metal roller 72 and a rubber roller 74, said metal roller 72 having circular grooves or being threaded, or being a flat metal roller.
  • the tow is stretched, the stretching being accomplished by driving the metal roller 72 at a rotational speed faster than driven roll 62.
  • the rotational speed of roll 72 is between 20-60 percent faster than roll 62, preferably 30-50 percent.
  • Each of the roller assemblies 40, 60 & 70 are conventional and well known; they include an arrangement for applying a pressure on one of the rolls in the assembly to urge the two rolls in the assembly into engagement with one another at a pre-determined pressure level.
  • the nip pressure between the rollers of assembly 70 is from about 1 psi to about 40 psi, preferably from about 20 psi to about 30 psi.
  • the tow emerging from assembly 70 is referred to hereafter as tow 14.
  • the grooves or threads of roller 64 and 74 are of a design or orientation known to those skilled in the art of tow processing or opening.
  • the fibers which emerge from assembly 70 are substantially deregistered or opened, suitable for further opening or forming into a lofty rectangular structure.
  • Substantial deregistration or blooming means that 90% or more, preferably 95% or more, of the fibers constituting the rectangular structure or rectangular tow are spaced apart by a distance greater than the distance between the fibers when the tow 14 was removed from bale 12.
  • tow 14 After emerging from assembly 70, tow 14 is passed by an optional static eliminating bar 101 to remove any static charge which might be present on tow 14 and which might interfere with subsequent operations necessary in the formation of an absorbent structure.
  • tow 14 is transported to an optional liquid additive assembly 80 which includes a liquid holding tank, a metering pump 84 and liquid dispenser applicators 86 within assembly 80 for dispersing liquids onto tow 14.
  • the liquid dispersal applicators 86 may be spray nozzles, disk applicators, rotating brush applicators, wick contact rolls and similar devices of conventional design known to those skilled in the art.
  • Liquids which can be dispersed onto tow 14 include water; hydrophilic liquids such as alcohols, glycols, dimethyl sulfide, ketones, ethers and similar substances; plasticizers such as Fiberset 100 or Fiberset 200 (Henkel Corporation, Cincinnati, Ohio); surfactants; and solutions containing plasticizers, surfactants and similar substances known to those skilled in the art.
  • the liquid or solutions can be applied to either or both sides of tow 14 as it passes through assembly 86, and additionally can be applied in specific patterns of multiple liquids to create unique effects for transferring or storing liquids in an absorbent composite structure in which the rectangular tow 14 is included.
  • the tow 14 After emerging from the air opening jet 240, the tow 14 is delivered to optional assembly 120 where solid substances, for example, superabsorbent polymers (SAP), glues, adhesives, fragrances, wood pulp, deodorizers, anti-microbial agents and similar substances can be applied to tow 14 by equipment such as a streamout feeder fabricated by Solids Flow, Inc. of Fort Mill, South Carolina.
  • solid substances for example, superabsorbent polymers (SAP), glues, adhesives, fragrances, wood pulp, deodorizers, anti-microbial agents and similar substances can be applied to tow 14 by equipment such as a streamout feeder fabricated by Solids Flow, Inc. of Fort Mill, South Carolina.
  • SAP may be delivered as a powder or a slurry vertically downwards onto tow 14.
  • the low density, open, rectangular tow band structure exiting air jet 240 permits particles of solids to evenly distribute within the tow fiber structure.
  • the fiber structure with evenly distributed solid particles can quickly be delivered to a subsequent process so
  • tow 14 is delivered to an optional speed delivery assembly 90 comprising, among other things, a driven roller 92 and a roller 94, either or both of which may have a rubber or metal surface for contact with tow 14.
  • Driven roller 92 controls the overall operation of the process and the speed of the tow 14 as it is delivered to another process such as a diaper or absorbent composite forming machine.
  • driven roller 92 and driven roller 72 are operated at speeds such that the surface speed ratio (72/92) is from about 1.0:1.0 to about 3.0:1.0, preferably 1.8:1.0 to 2.2:1.0.
  • the linear speed of roll 92 is typically controlled by the line speed of a diaper or absorbent composite forming process to which the lofty rectangular tow structure is being fed.
  • tow 14 is delivered directly to a diaper or absorbent composite forming process without the use of delivery speed assembly 90.
  • the diaper or absorbent composite process acts as the delivery or takeaway speed control.
  • the tow band structure with solids and applied liquids is nipped between rollers or wrapped around a driven single roller and pulled away from the air jet 240. Tissues or other webs can be introduced to encapsulate the fiber solids structure.
  • Additional optional static eliminating bars, elements 102 and 103 may be positioned between the air opening jet 240 and the liquids addition assembly 80, and after the air opening jet 240.
  • Static eliminating bars 100, 101, 102, and 103 can facilitate controlling the processability of tow 14 by limiting static electricity and controlling the shape of the rectangular structure of tow 14.
  • Additional static eliminating bars may be employed as required and are recommended when the moisture content in the environment is low.
  • Such additional anti-static bars may not only be located after assemblies 60, 70 and 80, but also between assemblies 60 and 40, 40 and 130, and 120 and 90.
  • Preferred embodiments have at least static eliminating bars 100, 101, and 102.
  • the air opening jet 240 of the present invention includes a housing 242 that is formed, at one of its ends, with an inlet opening 244.
  • the inlet opening 244 has a generally rectangular configuration that corresponds generally to the shape of the partially opened tow 14 which is received in the inlet opening 244 as described above.
  • the housing 242 also includes an outlet opening 246 which, as best seen in Fig. 5, also has a rectangular configuration that corresponds to the desired shape of the tow leaving the air opening jet apparatus 240.
  • An air jet is formed adjacent the inlet end of the housing 242, and it includes a source of compressed air 250 and a conventional control valve 252 for regulating the flow of compressed air from the compressed air source 250 to an air manifold, 254 through which the compressed air is delivered to jet orifices 256 which form a conventional jet of air for moving the tow 14 through a central passageway 258 in the housing 242 as will be explained in greater detail presently.
  • a source of compressed air 250 and a conventional control valve 252 for regulating the flow of compressed air from the compressed air source 250 to an air manifold, 254 through which the compressed air is delivered to jet orifices 256 which form a conventional jet of air for moving the tow 14 through a central passageway 258 in the housing 242 as will be explained in greater detail presently.
  • the passageway 258 has a gradually increasing cross-sectional area in the direction of movement of the tow 14 so as to provide a forming chamber 260 downstream of the air jet 248, and this forming chamber 260 also preferably has a generally rectangular configuration that corresponds to the rectangular shape of the tow 14.
  • An accumulating chamber 262 is located adjacent the outlet end of the housing 242 and downstream of the forming chamber 260, and the accumulating chamber 262 has a vertical dimension which is greater than the outlet opening 264 of the forming chamber 260, and it also is preferably formed with a rectangular configuration that will permit the opened tow 14 passing into the accumulating chamber 262 from the forming chamber 260 to accumulate within the accumulating chamber 262 and ultimately be withdrawn from the housing 242 through the outlet opening 246 at different flow rates and in the preferred rectangular shape of the tow 14.
  • a pair of plates 268, each having a large number of perforations 270 therein, are disposed in the accumulating chamber 262 and in the path of the tow 14 as it exits the forming chamber 260 and enters the accumulating chamber 262.
  • the plates 268 are fixed in place within the accumulating chamber 262 by a plurality of bolts 272 that maintain the plates 268 in fixed positions within the accumulating chamber 262.
  • the housing 242 also includes a pair of side plates 274 which extend along both sides thereof (see Fig. 7) to enclose the sides of the accumulating chamber 262 and the forming chamber 260, and each of the side plates 274 is formed with a plurality of perforations 276 which are located generally at a position where the carrier air leaves the forming chamber 260 and enters the accumulating chamber 262, whereby some of the carrier air can be discharged through the perforations 276.
  • compressed air from the compressed air source 250 flows to the air jet 248 at a flow rate controlled by the control valve 252, and the jet of air formed by the orifices 256 will move the tow 14 through the forming chamber 260.
  • the carrier air will partially open and expand the tow 14 so that it gradually increases in cross-sectional area in conformity with the gradually increasing cross-sectional area of the forming chamber 260.
  • the tow exits the forming chamber 260 and enters the accumulating chamber 262, it first opens even further to correspond to the vertical distance between the upstream ends of the perforated plates 268 (see Fig. 3), and the tow 14 engages the inner surfaces of the perforated plates 2 which are disposed in the path of the tow 14.
  • the air passing outwardly through the perforations 270 urges the tow 14 into frictional engagement with the facing inner surfaces of the perforated plates 268, and this frictional engagement creates a braking action on the tow 14 which retards the movement of the tow 14 through the accumulating chamber 262 and causes the tow to densify and accumulate in the accumulating chamber 262 at a density greater than it had in the forming chamber 260, after which the opened and now densified tow 14 exits the accumulating chamber 262 through the outlet opening 246 at different flow rates.
  • the tow 14 which exits through the outlet opening 246 has a desired and uniform density throughout the generally rectangular shape of the tow 14, and the present invention provides a unique and very desirable method of properly controlling the density of the exiting tow 14. More specifically, it will be apparent that the flow rate of the carrier air will determine the retarding or braking action applied to the tow 14 as it passes between the perforated plates 268. If the flow rate of the carrier air is increased, the carrier air passing outwardly through the perforations 270 in the plates 268 will urge the tow 14 into engagement with the plates 268 with a greater force, and will thereby increase the retarding or braking action that is applied to the tow 14. Conversely, if the flow rate of the carrier air is decreased, there will be a smaller braking action applied to the tow 14.
  • an air pressure of about 40 psi provides a desirable density of the tow 14 consisting of 0.004grams/ cm 3 exiting through an outlet opening having a width of 20 centimeters and a height of 2.5 centimeters.
  • FIGs. 8, 12, and 16 illustrate diagrammatically three alternative tow opening systems which utilize the air opening jet apparatus 240 of the present invention in a unique manner. More specifically, Fig. 8 illustrates a system in which a plurality of tow bands are fed into the inlet of the air jet opening apparatus 240. In Fig. 8, where the individual components which are identical to the components described above in connection with Fig. 1 are identified by the same reference numerals, two tow bands 14A and 14B are illustrated, but it will be understood that more than two tow bands could be utilized, depending on the desired end product.
  • the two tow bands 14A and 14B are each fed from a tow bale and into a conventional banding jet 130A and 130B, respectively, which are described in greater detail herein.
  • both tow bands 14A and 14B are delivered to the nip of a pre-tension roller assembly 40 that consists of metal roller 42 and a rubber roller 44, all as described above in connection with Fig. 1.
  • the pre-tension roller assembly 40 After the combined tow band leaves the pre-tension roller assembly 40, it is fed through the same series of components as that described in connection with Fig. 1.
  • Fig. 9 schematically depicts in transverse cross-section the resultant end product exiting from the air opening jet 240 in the system of Fig. 8, wherein the air banding jets 130A and 130B are set up to deliver the individual tow bands 14A and 14B in identical widths and in precise widthwise overlying registration with respect to one another.
  • the pre-tension roller assembly 40 and the roller assemblies 60, 70 effectively produce a substantial degree of initial intermixing of the filaments of the tow bands 14A and 14B following which the air opening jet 240 effectively causes the individual filaments in the two tow bands 14A and 14B to become substantially completely intermixed with one another into a composite web wherein the individual filaments of the tow bands 14A and 14B are commingled with one another essentially throughout the entire widthwise extent and through essentially the entire thickness of the web, as schematically depicted in Fig. 9.
  • each individual tow band 14A and 14B can be individually controlled by the operation of the conventional air banding jets 130A and 130B to vary the width of the tow bands 14A and 14B which are simultaneously delivered to the air opening jet 240 to provide a unique product, one example of which is illustrated in Fig. 10.
  • the tow bands 14A and 14B may, if desired, be initially fed from the tow bales through conventional guide components (not shown) that flatten and orient the tow bands 14A and 14B in a manner well known in the art, and when the tow bands 14A and 14B reach the air banding jets 130A and 130B the tow bands are spread in a direction perpendicular to the direction of movement of the tow bands to thereby open the two tow bands 14A and 14B within the banding jets 130A and 130B.
  • the widths of the tow bands 14A and 14B can be varied by the air banding jets 130A and 130B so that the ultimate product delivered from the air opening jet 240 has a particular desired composite tow structure.
  • Fig. 10 illustrates in transverse cross-section the end product exiting from the air opening jet 240 in the system of Fig. 8 set up such that the air banding jet 130A delivers a narrower tow band 14A centered in overlying relation with respect to a larger and wider tow band 14B delivered by the air banding jet 130B.
  • roller assemblies 40, 60, 70 followed by the air opening jet 240 effectively causes the individual filaments of the tow bands 14A and 14B to become commingled into a composite web wherein the central lengthwise region of the web has the filaments of the two tow bands 14A and 14B commingled substantially throughout, but the outer edgewise regions of the composite web will be comprised substantially entirely of the filaments of the wider tow band 14B, as schematically represented in Fig. 10.
  • Fig. 11 is a schematic depiction of a lengthwise cross-section taken through either of the composite tow webs of Figs. 9 or 10 along section lines 11-11 showing the crimped nature of the tow filaments and schematically illustrating the intimate commingling of the filaments of the tows 14A and 14B, characterized in that the respective filaments of the tows essentially cannot be distinguished from one another.
  • Fig. 8 many other variations of composite multi-tow web products may be produced as a result of the processing system of Fig. 8 as well as other possible alternative processing systems of the present invention, such as those of Figs. 12 and 16 as will be explained in greater detail below.
  • FIG. 12 Another alternate processing system using the unique air opening jet 240 is illustrated in Fig. 12, and, again, to the extent that the components illustrated in Fig. 12 are identical to those in Fig. 1, the same reference numerals are used and the details need not be described again here.
  • the tow bands 14A and 14B are fed from the tow bales (as shown in Fig. 8) to the individual air banding jets 130 in the same manner as that described above in connection with Fig. 8.
  • the tow bands 14A and 14B are each processed individually through all of the components which act upon the single tow band 14 in Fig.
  • additives or no additives can be applied to either or both of the tow bands 14A and 14B to achieve separate effects for each tow component, such as varying the super absorbent polymer containment, the solids attachment, or the fluid distribution enhancement characteristics of the respective tow bands 14A and 14B.
  • additives may also be applied to the resultant composite tow web downstream of the air opening jet 240.
  • the use of separate respective pre-tension roller assemblies 40, roller assemblies 60, 70 and liquid additive assemblies 80 for the two respective tow bands 14A and 14B in the system of Fig. 12 prevents any intermixing of the tow bands 14A and 14B prior to delivery into the air opening jet 240.
  • the individual filaments of the two tow bands 14A and 14B are intermixed only via the action of the air opening jet 240 and, hence, to a lesser extent than in the composite web produced by the system of Fig. 8. More specifically, the composite tow web produced by the system of Fig.
  • These three regions are schematically depicted in transverse cross-section by the composite tow webs of Figs. 13 and 14, Fig.
  • FIG. 13 depicting an embodiment of the composite tow web produced by the system of Fig. 12 wherein the tows 14A and 14B are of the same width and overlie one another in widthwise registry and Fig. 14 illustrating an alternative embodiment of composite tow, similar to that of Fig. 10, wherein the tow 14A is of a narrower widthwise extent centered in overlying relation with respect to the wider tow 14B.
  • Fig. 15 illustrates schematically the three regions of the composite tow web of Figs. 13 and 14 in lengthwise cross-section, similar to that of Fig. 11.
  • the composite tow web space produced by the system of Fig. 12 has the respective filaments of the individual tow bands 14A, 14B substantially commingled with one another predominately only in the region of the interface between the tow bands 14A and 14B when delivered into the air opening jet 240.
  • the ability to utilize a plurality of individually controlled and/or processed tow bands in combination with the air opening jet 240 provides an opportunity for producing a wide variety of products that have a structure and composition which can be tailored to a particular function.
  • a composite tow web structure that is particularly well suited to serve as a component of an absorbent disposable device, such as a disposable diaper.
  • a composite tow structure of an embodiment such as illustrated in Figs. 10 or 14 would be suitable for this particular application, and would consist of a tow band 14A having a higher denier units per filter (DPF), e.g., 6-8 DPF, and a total denier of between 12,000 to 20,000.
  • DPF denier units per filter
  • Tow band 14A would be oriented in the middle of the composite structure as illustrated in Figs. 10 or 14 so that it would be in contact with, or closely adjacent to, the initial fluid insult zone of the absorbent disposable device, and the higher DPF in the tow band 14A will provide improved fluid acquisition because of its higher strength and resistance to collapse when hydrated.
  • the banding jet 130A in Fig. 8 or the banding jet 130 applied to tow band 14A in Fig. 12 would restrict the width of tow band 14A to approximately 80 mm. If the system in Fig. 12 is utilized, the liquid applied to tow band 14A, via liquid application assembly 80, would be a surfactant that will enhance fluid management within the fluid acquisition structure.
  • the tow band 14B would have a lower DPF, e.g., 2-3, with a total denier of between 30,000-40,000, and tow band 14B would be oriented on the bottom of the composite structure so that it would be the main core body of the absorbent disposable device.
  • the lower DPF tow band structure would provide improved super absorbent polymer containment because of the higher density, larger fiber surface contact area and a larger number of individual fibers.
  • a 2.0 DPF/40,000 total denier tow band 14B would have approximately 20,000 separate fibers, whereas a 6.0 DPF/15,000 total denier tow band 14A would have only about 2,500 separate fibers.
  • the banding jet 130B would restrict the width of the tow band 14B to 150 mm, which would be the full inlet width of the air opening jet 240, so that the composite tow structure exiting the air opening jet 240 would have a configuration as diagrammatically shown in Fig. 10.
  • the liquid applied to the tow band 14A, via assembly 80 would be preferably a bonding agent such as a plasticizer, water, or water-based adhesive to enhance the super absorbent polymer containment and/or solid attachment or containment within the structure of the tow band 14B.
  • one of the tow bands may be formed of filaments which comprise a fusible bicomponent fiber material which may be utilized to bind together the filaments of the tow bands 14A and 14B by subjecting the composite tow web to a subsequent heat treatment.
  • filaments which comprise a fusible bicomponent fiber material which may be utilized to bind together the filaments of the tow bands 14A and 14B by subjecting the composite tow web to a subsequent heat treatment.
  • the ability provided by the present invention to selectively combine and intermix differing tow bands into a composite tow web may enable the resultant tow web to have superior or enhanced features, characteristics and/or performance in comparison to opened tow webs made of a single tow band.
  • experiments were conducted comparing a composite tow web made in accordance with the system of Fig. 8 described above and opened tow webs made of a single tow band utilizing the system of Fig. 1. The results of such experiments are compiled in the charts of Figs. 19 and 20.
  • Each web was identically treated to apply thereto a layer of a super absorbent polymer (SAP), appropriate porous and non-porous glue layers, and outer coverings of tissue, to produce from each web an absorbent device such as utilized in a disposable diaper as described above.
  • SAP super absorbent polymer
  • Two sample devices were made of differing composite tow webs produced by the system of Fig. 8 and three sample devices were made of single tow webs produced by the system of Fig. 1, and the devices were then tested to determined their liquid acquisition and absorption capabilities.
  • the differing physical characteristics of the sample devices are compiled for comparative purposes in the chart of Fig. 19, while the results of the testing of such devices are compiled in the chart of Fig. 20.
  • the sample devices made with composite tows utilizing the system of Fig. 8 are identified as Samples 6-0601 and 7-0601, while the sample devices made of a single tow utilizing the system of Fig. 1 are identified as Samples 2-0601, 3-0601, and 4-0601.
  • the sample devices made with the composite tow webs achieved superior acquisition and absorption results in comparison to the devices made with the single tow webs, even as to the single tow webs having the same average denier per filament as the composite tow webs. It is reasonable to conclude from these experiments that the composite tow webs provide for better containment of the super absorbent polymer than webs made of a single tow which, in turn, indicates that the tow structure has a higher degree of stability.
  • FIG. 16 Another unique system utilizing the air opening jet 240 of the present invention is illustrated in Fig. 16 where, again, like reference numerals are used to identify the same components of the system as those described above in conjunction with Fig. 1.
  • each of the tow bands 14A, 14B are passed separately through a series of processing steps, and then fed to the intake of a separate air opening jet 240. More specifically as illustrated in Fig. 16, each two band 14A and 14B are passed individually through a banding jet 130, then through roller assemblies 40, 60 and 70 as described above, and then through the liquid addition assembly 80, after which each tow band is fed to the intake of a separate air opening jet 240.
  • the tow bands exiting the air opening jets 240 are then combined and jointly delivered to the same components that are downstream of the air opening jet 240 as illustrated in Fig. 1, and when the combined tow bands are moved through the speed delivery roller assembly 90, a composite multi-tow web is created as diagrammatically illustrated in Figs. 17 and 18.
  • the tow bands 14A, 14B are individually opened and processed in a separate air opening jet 240 and then combined together, the tow bands 14A, 14B, have a generally laminated layered relationship, as is depicted schematically in Figs 17 and 18, with very little entanglement of fibers of the two tow bands, 14A, 14B, as compared with the multi-tow webs illustrated in Figs. 9, 10, 13 and 14.
  • each layer in the product can be provided with separate and individualized finishes at the liquid additive stations 80, and, if desired, one or both of the liquid additive stations 80, or an additional processing station downstream of air opening jets 240, may insert a desired material (e.g. a super-absorbent polymer) between the layers formed by the tow bands 14A, 14B.
  • a desired material e.g. a super-absorbent polymer

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Nonwoven Fabrics (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Orthopedics, Nursing, And Contraception (AREA)
  • Looms (AREA)
EP00122227A 1999-10-25 2000-10-17 Vorrichtung, Verfahren und System zur Ausbreitung eines Faserbündels durch Luftstrahlen und damit hergestellte Faserbahn Withdrawn EP1096047A1 (de)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US679832 1984-12-10
US679681 1996-07-11
US09/426,268 US6253431B1 (en) 1999-10-25 1999-10-25 Air opening jet apparatus
US426268 1999-10-25
US67983200A 2000-10-05 2000-10-05
US09/679,681 US6543106B1 (en) 1999-10-25 2000-10-05 Apparatus, method and system for air opening of textile tow and opened textile tow web produced thereby

Publications (1)

Publication Number Publication Date
EP1096047A1 true EP1096047A1 (de) 2001-05-02

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EP00122227A Withdrawn EP1096047A1 (de) 1999-10-25 2000-10-17 Vorrichtung, Verfahren und System zur Ausbreitung eines Faserbündels durch Luftstrahlen und damit hergestellte Faserbahn

Country Status (8)

Country Link
EP (1) EP1096047A1 (de)
JP (3) JP3616323B2 (de)
KR (1) KR20010112035A (de)
AU (1) AU6809300A (de)
BR (1) BRPI0006737B1 (de)
CA (1) CA2324081C (de)
MX (1) MXPA00010392A (de)
NO (1) NO20005354L (de)

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DE102008003369A1 (de) 2008-01-08 2009-07-09 Hauni Maschinenbau Aktiengesellschaft Ausbreiterdüse
EP2377978A1 (de) * 2010-04-19 2011-10-19 3B-Fibreglass SPRL Verfahren und Vorrichtung zur Ausbreitung von Fasersträngen
WO2011131670A1 (en) * 2010-04-19 2011-10-27 3B-Fibreglass Sprl Method and equipment for reinforcing a substance or an object with continuous filaments
WO2013074609A1 (en) * 2011-11-16 2013-05-23 Celanese Acetate Llc Acquisition distribution layers produced from continuous tow bands and systems and methods relating thereto
US8623248B2 (en) 2011-11-16 2014-01-07 Celanese Acetate Llc Methods for producing nonwoven materials from continuous tow bands
EP2893821A1 (de) 2014-01-13 2015-07-15 HAUNI Maschinenbau AG Kanalgehäuse für eine Ausbreiterdüse zum Ausbreiten von für die Herstellung von Zigarettenfiltern verwendetem Tow und Verfahren zum Ausbreiten von Tow
EP2787107A4 (de) * 2011-11-29 2015-09-02 Daicel Corp Vorrichtung zur herstellung eines langen fasergeleges
US9849638B2 (en) 2013-02-08 2017-12-26 The Procter & Gamble Company Process and apparatus for fluffing a cleaning implement
CN107916496A (zh) * 2017-12-01 2018-04-17 陈淑芳 一种仿人工弹制棉花机
CN112041488A (zh) * 2018-08-23 2020-12-04 株式会社大赛璐 开纤体成型装置及开纤体制造装置

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US7305739B2 (en) * 2004-09-15 2007-12-11 Celanese Acetate, Llc Apparatus for tow opening
JP4519620B2 (ja) * 2004-11-29 2010-08-04 大王製紙株式会社 トウの加工設備
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US8461066B2 (en) * 2007-08-02 2013-06-11 Celanese Acetate Llc Nonwoven from bulked filament tow
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JP6653632B2 (ja) * 2016-07-05 2020-02-26 株式会社ダイセル 吸収性物品製造装置及び吸収性物品の製造方法
JP2020033655A (ja) * 2018-08-27 2020-03-05 株式会社ダイセル 開繊体、開繊体製造装置、及び開繊体の製造方法

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Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102008003369A1 (de) 2008-01-08 2009-07-09 Hauni Maschinenbau Aktiengesellschaft Ausbreiterdüse
EP2377978A1 (de) * 2010-04-19 2011-10-19 3B-Fibreglass SPRL Verfahren und Vorrichtung zur Ausbreitung von Fasersträngen
WO2011131670A1 (en) * 2010-04-19 2011-10-27 3B-Fibreglass Sprl Method and equipment for reinforcing a substance or an object with continuous filaments
EP2780498A4 (de) * 2011-11-16 2015-07-22 Celanese Acetate Llc Vliesstoffe aus durchgehend gezogenen bändern sowie vorrichtungen und verfahren dafür
WO2013074609A1 (en) * 2011-11-16 2013-05-23 Celanese Acetate Llc Acquisition distribution layers produced from continuous tow bands and systems and methods relating thereto
US8623248B2 (en) 2011-11-16 2014-01-07 Celanese Acetate Llc Methods for producing nonwoven materials from continuous tow bands
EP2787107A4 (de) * 2011-11-29 2015-09-02 Daicel Corp Vorrichtung zur herstellung eines langen fasergeleges
US9849638B2 (en) 2013-02-08 2017-12-26 The Procter & Gamble Company Process and apparatus for fluffing a cleaning implement
DE102014200397A1 (de) 2014-01-13 2015-07-16 Hauni Maschinenbau Ag Kanalgehäuse für eine Ausbreiterdüse zum Ausbreiten von für die Herstellung von Zigarettenfiltern verwendetem Tow und Verfahren zum Ausbreiten von Tow
EP2893821A1 (de) 2014-01-13 2015-07-15 HAUNI Maschinenbau AG Kanalgehäuse für eine Ausbreiterdüse zum Ausbreiten von für die Herstellung von Zigarettenfiltern verwendetem Tow und Verfahren zum Ausbreiten von Tow
CN107916496A (zh) * 2017-12-01 2018-04-17 陈淑芳 一种仿人工弹制棉花机
CN107916496B (zh) * 2017-12-01 2020-06-09 绍兴伟乐服饰有限公司 一种仿人工弹制棉花机
CN112041488A (zh) * 2018-08-23 2020-12-04 株式会社大赛璐 开纤体成型装置及开纤体制造装置

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CA2324081C (en) 2005-12-06
JP4030525B2 (ja) 2008-01-09
MXPA00010392A (es) 2002-07-02
NO20005354D0 (no) 2000-10-24
KR20010112035A (ko) 2001-12-20
JP2001279542A (ja) 2001-10-10
JP3616323B2 (ja) 2005-02-02
BR0006737A (pt) 2002-12-31
NO20005354L (no) 2001-04-26
BRPI0006737B1 (pt) 2016-09-13
CA2324081A1 (en) 2001-04-25
AU6809300A (en) 2001-04-26
JP2005048348A (ja) 2005-02-24
JP2004244794A (ja) 2004-09-02
JP4044912B2 (ja) 2008-02-06

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